92-20521-31 rev. 04 hka ans hkl series premium effieiciency...

INSTALLATION INSTRUCTIONSAIR HANDLERS

FEATURING R-22 REFRIGERANT:(-)HKA Premium Efficiency

FEATURING EARTH-FRIENDLYR-410AREFRIGERANT:(-)HKL Premium Efficiency

r e f r i g e r a n te a r t h f r i e n d l y r e f r i g e r a n t

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORT ANT SAFETY INFORMA TION!!

DO NOT DESTROY THIS MAN UALPLEASE READ CARE FULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SER VICEMAN

THESE INSTRU CTIONS ARE INTENDED AS AN AID TOQ UALIFIED,LICENSED SER VICE PERSONNEL FOR PRO PERINSTALLATION,AD JUSTMENT AND OPERATION OF THIS UNIT.READ THESE INSTRU CTIONS THORO U GHLY BE FOREATTEM PTING INSTALLATION OR OPERATION .FAILURE TO FOL -LO W THESE INSTR U CTIONS MAY RES U LT IN IM PRO PERINSTALLATION,AD JUSTMENT ,SER VICE OR M AINTENANCEPOSSIBLY RES U LTING IN FIRE, ELECTRICAL SHOC K ,PRO PERTY DAMAGE ,PERSONAL INJURY OR DEATH .

W ARNING!�WARNING!

These instructions are intended as an aid to qualified licensed servicepersonnel for proper installation, adjustment andoperation of this unit. Read these instructions thoroughly beforeattempting installation or operation. Failure to follow these instruc-tions may result in improper installation, adjustment,service or maintenance possibly resulting in fire, electrical shock,property damage, personal injury or death. ISO 9001:2000

92-20521-31-04SUPERSEDES 92-20521-31-03

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CONTENTS1.0 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Important Information About Efficiency and Indoor Air Quality . . . . . . . 52.2 Model Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.3 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.4 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.5 Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.0 APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.1 Zoning Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93.2 Vertical Upflow & Horizontal Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.3 Vertical Downflow & Horizontal Right . . . . . . . . . . . . . . . . . . . . . . . . . 103.4 Installation in an Unconditioned Space . . . . . . . . . . . . . . . . . . . . . . . . 12

4.0 ELECTRICALWIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.1 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124.2 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.3 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134.4 Blower Motor Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144.5 Electric Heat Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.5A Heater Kit Supplemental Information . . . . . . . . . . . . . . . . . . . . . 175.0 ECM MOTOR INTERFACE CONTROL BOARD . . . . . . . . . . . . . . . . . . . . . 18

5.1 ECM Motor Interface Control & Settings . . . . . . . . . . . . . . . . . . . . . . . 185.2 Using the On-board LED to Determine Blower CFM . . . . . . . . . . . . . . 195.3 Cooling Airflow Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195.4 Cooling Airflow Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205.5 Heating Airflow Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.6 Cooling Delay Profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215.7 Cooling Mode Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.7A Typical Thermostat Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . 225.8 On Demand Dehumidification Airflow Adjustment . . . . . . . . . . . . . . . . 23

5.8A Explanation of Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236.0 AIRFLOW PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.1 Airflow Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257.0 DUCTWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268.0 REFRIGERANT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

8.1 TEV Sensing Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278.2 Condensate Drain Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278.3 Duct Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

9.0 AIR FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2810.0 SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

10.1 Cooling (cooling only & heat pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2810.2 Heating (electric heat only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2810.3 Heating (heat pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.4 Defrost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.5 Emergency Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2910.6 Room Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

11.0 CALCULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.1 Calculating Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.2 Calculating BTUH Heating Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.3 Calculating Airflow CFM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3011.4 Calculating Correction Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

12.0 PRE-START CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3113.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

13.1 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3213.2 Indoor Coil/Drain Pan/Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3213.3 Blower Motor & Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3213.4 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3213.5 Blower Assembly Removal & Replacement. . . . . . . . . . . . . . . . . . . . . 3213.6 Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3313.7 ECM Control Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 3413.8 Blower Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

14.0 REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3615.0 ACCESSORIES - KITS - PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1.0 SAFETY INFORMATION

! WARNING (SEE WARNINGS IN REGARD TO DUCTWORK)

Do not install this unit in manufactured (mobile) homes. Improper installation is morelikely in manufactured housing due to ductwork material, size, location, and arrange-ment. Installations in manufactured housing can cause a fire resulting in propertydamage, personal injury or death.EXCEPTION: Manufactured housing installations are approved only with documen-tation by a recognized inspection authority that the installation has been made incompliance with the instructions and all warnings have been observed.

! WARNING (SEE SECTION 3.2: VERTICAL UPFLOW & HORIZONTAL LEFT)

If unit is to be installed without an indoor coil, return air duct, or plenum, it must not beinstalled directly over combustible material. If installed without an indoor coil with areturn duct or plenum, the air plenum or duct must have a solid sheet metal bottomwith no return air openings, registers or flexible air ducts located directly under the unit.Exposing combustible material to the return opening of an upflow unit without anindoor coil can cause a fire resulting in property damage, personal injury or death.

Continued on next page �

! WARNINGDuct leaks can create an unbalanced system and draw pollutants such as dirt,dust, fumes and odors into the home causing property damage. Fumes andodors from toxic, volatile or flammable chemicals, as well as automobile exhaustand carbon monoxide (CO), can be drawn into the living space through leakingducts and unbalanced duct systems causing personal injury or death (seeFigure 1).• If air-moving equipment or ductwork is located in garages or off-garage stor-age areas - all joints, seams, and openings in the equipment and duct must besealed to limit the migration of toxic fumes and odors including carbon monox-ide frommigrating into the living space.

• If air-moving equipment or ductwork is located in spaces containing fuel burn-ing appliances such as water heaters or boilers - all joints, seams, and open-ings in the equipment and duct must also be sealed to prevent depressuriza-tion of the space and possible migration of combustion byproducts includingcarbon monoxide into the living space.

! WARNINGUse of this air-handler during construction is not recommended. If operation dur-ing construction is absolutely required, the following temporary installationrequirements must be followed:Installation must comply with all Installation Instructions in this manual includingthe following items:• Properly sized power supply and circuit breaker/fuse• Air-handler operating under thermostatic control;• Return air duct sealed to the air-handler;• Air filters must be in place;• Correct air-flow setting for application• Removing the coil and storing it in a clean safe place is highly recommendeduntil construction is completed and the outdoor unit is installed.

• Clean air-handler, duct work, and components including coil upon completionof the construction process and verify proper air-handler operating conditionsaccording as stated in this instruction manual.

• NOTE: Electric strip heater elements tend to emit a burning odor for a few daysif dust has accumulated during construction. Heater elements are easily dam-aged. Take great care when cleaning them. Low pressure compressed air isrecommended for cleaning elements.

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! WARNING (SEE SECTION 13.5: BLOWER ASSEMBLY REMOVAL & REPLACEMENT)

If removal of the blower assembly is required, all disconnect switches supplyingpower to the airhandler must be de-energized and locked (if not in sight of unit) sothe field power wires can be safely removed from the blower assembly. Failure to doso can cause electrical shock resulting in personal injury or death.

! WARNINGPROPOSITION 65: This appliance contains fiberglass insulation. Respirable particlesof fiberglass are known to the State of California to cause cancer.All manufacturer products meet current Federal OSHAGuidelines for safety.California Proposition 65 warnings are required for certain products, which are notcovered by the OSHA standards.California's Proposition 65 requires warnings for products sold in California that con-tain or produce any of over 600 listed chemicals known to the State of California tocause cancer or birth defects such as fiberglass insulation, lead in brass, and com-bustion products from natural gas.All “new equipment”shipped for sale in California will have labels stating that theproduct contains and/or produces Proposition 65 chemicals. Although we have notchanged our processes, having the same label on all our products facilitates manu-facturing and shipping. We cannot always know “when, or if”products will be sold inthe California market.Youmay receive inquiries from customers about chemicals found in, or produced by,some of our heating and air-conditioning equipment, or found in natural gas used withsome of our products. Listed below are those chemicals and substances commonlyassociated with similar equipment in our industry and other manufacturers.• GlassWool (Fiberglass) Insulation• CarbonMonoxide (CO).• Formaldehyde• BenzeneMore details are available at the websites for OSHA (Occupational Safety and HealthAdministration), at www.osha.gov and the State of California’s OEHHA (Office ofEnvironmental Health Hazard Assessment), at www.oehha.org. Consumer educationis important since the chemicals and substances on the list are found in our dailylives. Most consumers are aware that products present safety and health risks, whenimproperly used, handled andmaintained.

Continued on next page �

! WARNING (SEE SECTION 13.7: ECM CONTROL MODULE REPLACEMENT)Always have 240 volt power turned off to the furnace before attempting any replace-ment of the motor or control module. Failure to do so may result in serious equipmentdamage, personal injury or death.

! WARNING (SEE SECTION 4.0: ELECTRICAL WIRING)

Disconnect all power to unit before installing or servicing. More than one discon-nect switch may be required to de-energize the equipment. Hazardous voltagecan cause severe personal injury or death.

! WARNING (SEE SECTION 13.0: MAINTENANCE)Units with circuit breaker(s) meet requirements as a service disconnect switch, how-ever, if access is required to the line side (covered) of the circuit breaker, this side ofthe breaker(s) will be energized with the breaker(s) de-energized. Contact with theline side can cause electrical shock resulting in personal injury or death.

! WARNING (SEE SECTION 4.3: GROUNDING)

The unit must be permanently grounded. Failure to do so can result in electricalshock causing personal injury or death.

2.0 GENERAL INFORMATION2.1 IMPORTANT INFORMATION ABOUT EFFICIENCY AND INDOOR2.1 AIR QUALITYCentral cooling and heating equipment is only as efficient as the duct system that car-ries the cooled or heated air. To maintain efficiency, comfort and good indoor air quality,it is important to have the proper balance between the air being supplied to each roomand the air returning to the cooling and heating equipment.Proper balance and sealing of the duct system improves the efficiency of the heatingand air conditioning system and improves the indoor air quality of the home by reducing

CAUTION (SEE SECTION 3.2: VERTICAL UPFLOW & HORIZONTAL LEFT)Horizontal units must be configured for right hand air supply. Horizontal drain pan mustbe located under indoor coil. Failure to use the drain pan can result in property damage.

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! WARNING (SEE SECTION 6.0: DUCTWORK)

Do not, under any circumstances, connect return ductwork to any other heat producingdevice such as fireplace insert, stove, etc. Unauthorized use of such devicesmay resultin fire, carbonmonoxide poisoning, explosion, personal injury or property damage.

! WARNINGBecause of possible damage to equipment or personal injury, installation, service,and maintenance should be performed by trained, qualified service personnel.Consumer service is recommended only for filter cleaning/replacement. Never oper-ate the unit with the access panels removed.

! WARNING (SEE SECTION 3.3: VERTICAL DOWNFLOW & HORIZONTAL RIGHT)

The RXHB-17, RXHB-21, or RXHB-24 combustible floor base is required when cer-tain units are applied downflow on combustible flooring. Failure to use the base cancause a fire resulting in property damage, personal injury or death. See clearancesfor units requiring a combustible floor base. See the accessory section in this manualfor combustible floor base RXHB-.

! CAUTION (SEE SECTION 13.7: ECM CONTROL MODULE REPLACEMENT)Reversing the 5-pin connector on the ECM motor causes immediate failure of thecontrol module.

CAUTION (SEE SECTION 13.2: INDOOR COIL - DRAIN PAN - DRAIN LINE)In compliance with recognized codes, it is recommended that an auxiliary drain panbe installed under all evaporator coils or units containing evaporator coils that arelocated in any area of a structure where damage to the building or building contentsmay occur as a result of an overflow of the coil drain pan or a stoppage in the prima-ry condensate drain piping. See accessory section in this manual for secondary hori-zontal drain pan RXBM-.

CAUTIONWhen used on cooling applications, excessive sweating may occur when unit isinstalled in an unconditioned space. This can result in property damage.

! NOTICEImproper installation, or installation not made in accordance with theUnderwriters Laboratory (UL) certification or these instructions, can result inunsatisfactory operation and/or dangerous conditions and are not covered bythe unit warranty.

! NOTICEIn compliance with recognized codes, it is recommended that an auxiliary drainpan be installed under all evaporator coils or units containing evaporator coilsthat are located in any area of a structure where damage to the building or build-ing contents may occur as a result of an overflow of the coil drain pan or a stop-page in the primary condensate drain piping. See accessories section of theseinstructions for auxiliary horizontal overflow pan information (model RXBM).

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FIGURE 2MODEL NUMBER EXPLANATION

(-) H K A– HM 24 17 J ATRADEBRAND

CLASSIFICATION = AIR HANDLER

K = PREMIUM MODEL

REFRIGERANT = A = R-22L = R-410A

HM = A/C OR HEAT PUMPMULTI-POSITION (Upflow &Horizontal Left Is The FactoryConfiguration)

DESIGN VARIATIONA = 1ST DESIGNVOLTAGEJ = 208/240/1/60

CABINET SIZE17 = 17.5" (600-1200 CFM)21 = 21" (1400-1600 CFM)24 = 24.5" (1600-1800 CFM)

CAPACITY24 = 18000/24000 BTUH 48 = 42000/48000 BTUH36 = 30000/36000 BTUH 60 = 60000 BTUH

NOTES:1) J Voltage (230V) single phase air handler is designed to be used with single or three phase 230 volt power. In the case

of connecting 3-phase power to the air handler terminal block, bring only two leads to the terminal block. Cap, insulateand fully secure the third lead.

2) The air handlers are shipped from the factory with the proper indoor coil installed, and cannot be ordered without a coil.3) Electric heat elements are field-installed items.4) The air handlers do not have an internal filter rack. An external filter rack or other means of filtration is required.

2.2 MODEL NUMBER EXPLANATION (SEE FIGURE 2)

AVAILABLE MODELS(-)HKA-HM2417JA

(-)HKL-HM2417JA

(-)HKA-HM3617JA

(-)HKL-HM3617JA

(-)HKA-HM4821JA

(-)HKL-HM4821JA

(-)HKA-HM4824JA

(-)HKL-HM4824JA

(-)HKA-HM6024JA

(-)HKL-HM6024JA

FIGURE 1MIGRATION OF DANGEROUS SUBSTANCES, FUMES, AND ODORS INTO LIVING SPACES

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2.3 DIMENSIONS & WEIGHTS (SEE FIGURE 3)

FIGURE 3DIMENSIONS AND WEIGHTS -- SINGLE COIL UNITS

DIMENSIONAL DATA

MODELSIZE

UNITWIDTH“W” IN[mm]

UNITHEIGHT“H” IN[mm]

SUPPLYDUCT“A” IN.[mm] LO HI UNIT WITH

COIL (MAX. kW.)

AIR FLOWCOIL (NOM) [L/s]

UNIT WEIGHT / SHIPPINGWEIGHT (LBS.) [kg]

2417 171/2" [445] 421/2" [1080] 16" [409] 600 [283] 800 [378] 82/96 [37/44]

3617 171/2" [445] 421/2" [1080] 16" [409] 1000 [472] 1200 [566] 92/106 [37/48]

4821 21" [533] 501/2" [1283] 191/2" [495] 1400 [661] 1600 [755] 150/166 [68/75]

4824 241/2" [622] 551/2" [1410] 23" [585] 1600 [755] — 162/180 [73/81]

6024 241/2" [622] 551/2" [1410] 23" [585] — 1800 [850] 181/198 [82/90]

A-1038-01

NOTE: 24" CLEARANCE REQUIREDIN FRONT OF UNIT FOR FILTERAND COIL MAINTENANCE.ELECTRICAL CONNECTIONS

MAY EXIT TOP OR EITHER SIDE

HIGH VOLTAGE CONNECTION 7/8".1 3/32", 1 31/32" DIA. KNOCK OUTS.

LOW VOLTAGE CONNECTION5/8" AND 7/8" KNOCK OUT(OUTSIDE OF CABINET)

AUXILIARY DRAIN CONNECTION3/4" FEMALE PIPE THREAD (NPT)HORIZONTAL APPLICATION ONLY

PRIMARY DRAIN CONNECTION3/4" FEMALE PIPE THREAD (NPT)

AUXILIARY DRAIN CONNECTION3/4" FEMALE PIPE THREAD (NPT)UPFLOW/DOWNFLOW APPLICATIONONLY

LIQUID LINE CONNECTIONCOPPER (SWEAT)

VAPOR LINE CONNECTIONCOPPER (SWEAT)

2111/16

105/16

SUPPLY AIR

W

A

H

191/2RETURN AIR OPENING

UPFLOW UNIT SHOWN;UNIT MAY BE INSTALLED UPFLOW, DOWNFLOW.HORIZONTAL RIGHT, OR LEFT AIR SUPPLY.

Model Return Air Opening Return Air OpeningCabinet Size Width (Inches) Depth/Length (Inches)

17 157⁄8 193⁄421 193⁄8 193⁄424 227⁄8 193⁄4

RETURN AIR OPENING DIMENSIONS

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the amount of airborne pollutants that enter homes from spaces where the ductwork and/ or equipment is located. The manufacturer and the U.S. Environmental ProtectionAgency’s Energy Star Program recommend that central duct systems be checked by aqualified contractor for proper balance and sealing.

2.4 RECEIVINGImmediately upon receipt, all cartons and contents should be inspected for transit dam-age. Units with damaged cartons should be opened immediately. If damage is found, itshould be noted on the delivery papers, and a damage claim filed with the last carrier.• After unit has been delivered to job site, remove carton taking care not to damageunit.

• Check the unit rating plate for unit size, electric heat, coil, voltage, phase, etc. to besure equipment matches what is required for the job specification.

• Read the entire instructions before starting the installation.• Some building codes require extra cabinet insulation and gasketing when unit isinstalled in attic applications.

• If installed in an unconditioned space, apply caulking around the power wires, controlwires, refrigerant tubing and condensate line where they enter the cabinet. Seal thepower wires on the inside where they exit conduit opening. Caulking is required topre-vent air leakage into and condensate from forming inside the unit, control box,and on electrical controls.

• Install the unit in such a way as to allow necessary access to the coil/filter rack andblower/control compartment.

• Install the unit in a level position to ensure proper condensate drainage. Make sureunit is level in both directions within 1/8”.

• Install the unit in accordance with any local code which may apply and the nationalcodes. Latest editions are available from: “National Fire Protection Association, Inc.,Batterysmarch Park, Quincy, MA 02269.” These publications are:• ANSI/NFPA No. 70-(Latest Edition) National Electrical Code.• NFPA90A Installation of Air Conditioning and Ventilating Systems.• NFPA90B Installation of warm air heating and air conditioning systems.

• The equipment has been evaluated in accordance with the Code of FederalRegulations, Chapter XX, Part 3280.

! WARNING

! NOTICEImproper installation, or installation not made in accordance with theUnderwriters Laboratory (UL) certification or these instructions, can result inunsatisfactory operation and/or dangerous conditions and are not covered bythe unit warranty.

Duct leaks can create an unbalanced system and draw pollutants such as dirt,dust, fumes and odors into the home causing property damage. Fumes andodors from toxic, volatile or flammable chemicals, as well as automobile exhaustand carbon monoxide (CO), can be drawn into the living space through leakingducts and unbalanced duct systems causing personal injury or death (seeFigure 1).• If air-moving equipment or ductwork is located in garages or off-garage stor-age areas - all joints, seams, and openings in the equipment and duct must besealed to limit the migration of toxic fumes and odors including carbon monox-ide frommigrating into the living space.

• If air-moving equipment or ductwork is located in spaces containing fuel burn-ing appliances such as water heaters or boilers - all joints, seams, and open-ings in the equipment and duct must also be sealed to prevent depressuriza-tion of the space and possible migration of combustion byproducts includingcarbon monoxide into the living space.

! NOTICEIn compliance with recognized codes, it is recommended that an auxiliary drainpan be installed under all evaporator coils or units containing evaporator coilsthat are located in any area of a structure where damage to the building or build-ing contents may occur as a result of an overflow of the coil drain pan or a stop-page in the primary condensate drain piping. See accessories section of theseinstructions for auxiliary horizontal overflow pan information (model RXBM).

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2.5 CLEARANCES• All units are designed for “0” inches clearance to combustible material on all cabinetsurfaces.

• Some units require supply duct clearances and combustible floor bases depending onthe heating kW. The following table should be used to determine these requirements:Units with electric heating kW above that listed in the table require a one inch clear-ance to combustible material for the first three feet of supply plenum and ductwork.Additionally, if these units are installed downflow, a combustible floor base isrequired. See Accessories for Combustible Floor Base RXHB-XX.Units with electric heating kW equal to or less than the values listed in the table donot require supply ductwork clearances or combustible floor bases.

• Vertical units require clearance on at least one side of the unit for electrical connec-tions. Horizontal units require clearance on either top or bottom for electrical connec-tions. Refrigerant and condensate drain connections are made on the front of the unit.(See Figure 4.)

• All units require 24 inches maximum access to the front of the unit for service.• These units may be installed in either ventilated or nonventilated spaces.

3.0 APPLICATIONS3.1 ZONING SYSTEMSThe manufacturer does not currently provide or support zoning. However, zoning systemscan be installed with a variable speed air-handler as long as the zoning equipment manu-facturers specifications and installation instructions are met and followed.The preferred zoning method is to use a “bypass” system which is properly installed formaximum efficiency. In these systems, excess air is routed back through the system tobe used again – this is opposed to a “dump” system in which excess air is routed to azone where it is expected that the extra heat or cooling would be least noticed.If installed as a “bypass” system, the installation must have an optional freeze statinstalled to prevent the coil from icing with excess bypass cooling. Also, if the zoningequipment manufacturer provides a limit switch (usually provided by the zoning manufac-turer), this limit must be installed in the system to prevent the furnace from overheating.

FIGURE 4DIMENSIONS FOR FRONT CONNECT COIL

41/8

31/16

13/16 11/8

11/16

13/8

213/16

51/4

53/8

515/16

Model Cabinet Size 17 21 24Model Designation kW 15 20 25

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3.2 VERTICAL UPFLOW AND HORIZONTAL LEFTThe air handler unit is factory shipped for vertical upflow and horizontal left application.

• If return air is to be ducted, install duct flush with floor. Use fireproof resilient gasket 1/8to 1/4 in. thick between duct, unit and floor. Set unit on floor over opening.

• Support along the length of the unit, on all units installed horizontally. Do not supportor suspend unit from both ends without support in the center of the cabinet. If unit isto be supported or suspended from corners, run two reinforcing rails length of unitand support or suspend from reinforcing rails.

• Secondary drain pan kits RXBM- are required when the unit is configured for the hori-zontal left position over a finished ceiling and/or living space. (See Section 15.0:Accessories - Kits - Parts.)

3.3 VERTICAL DOWNFLOW AND HORIZONTAL RIGHTConversion to Vertical Downflow/Horizontal Right: A vertical upflow unit may be convertedto vertical downflow/horizontal right. (See Figure 5.) Remove the door and indoor coil andreinstall 180° from original position.

IMPORTANT: To comply with certification agencies and the National Electric Code forhorizontal right application, the circuit breaker(s) on field-installed electric heater kitsmust be re-installed per procedure below so that the breaker switch “on” position andmarking is up and, “off” position and marking is down.

- To turn breaker(s): Rotate one breaker pair (circuit) at a time starting with the one on theright. Loosen both lugs on the load side of the breaker. Wires are bundles with wire ties,one bundle going to the right lug and one bundle going to the left lug.

- Using a screwdriver or pencil, lift white plastic tab with hole away from breaker untilbreaker releases from mounting opening (see Figure 6).

- With breaker held in hand, rotate breaker so that “on” position is up, “off” position is downwith unit in planned vertical mounting position. Insert right wire bundle into top rightbreaker lug, ensuring all strands of all wires are inserted fully into lug, and no wire insula-tion is in lug.

FIGURE 5VERTICAL DOWNFLOW &HORIZONTAL RIGHT APPLICATIONS

CAUTIONHorizontal units must be configured for right hand air supply. Horizontal drain panmust be located under indoor coil. Failure to use the drain pan can result in propertydamage.

DETAIL AENSURE THE RETAIN-ING CHANNEL IS FULLYENGAGED WITH THE

COIL RAIL.RAILS

RAILS

11

- Tighten lug as tight as possible while holding circuit breaker. Check wires and make sureeach wire is secure and none are loose. Repeat for left wire bundle in left top circuitbreaker lug.

- Replace breaker by inserting breaker mounting tab opposite white pull tab in opening,hook mounting tab over edge in opening.

- With screwdriver or pencil, pull white tab with hole away from breaker while setting thatside of breaker into opening. When breaker is in place, release tab, locking circuit break-er into location in opening.

- Repeat above operation for remaining breaker(s) (if more than one is provided).

- Replace single point wiring jumper bar, if it is used, on line side of breaker and tightensecurely.

- Double check wires and lugs to make sure all are secure and tight. Check to make sureunit wiring to circuit breaker load lugs match that shown on the unit wiring diagram.

• Rotate unit into the downflow position, with the coil compartment on top and the blower com-partment on bottom.

• Reinstall the indoor coil 180° from original position. Ensure the retaining channel is fullyengaged with the coil rail. (See Figure 5, Detail A.)

• Secondary drain pan kits RXBM- are required when the unit is configured for the hori-zontal right position over a finished ceiling and/or living space. (See Section 15.0:Accessories - Kits - Parts.)

IMPORTANT: Units cannot be installed horizontally laying on or suspended from theback of the unit.

! WARNINGThe RXHB-17, RXHB-21, or RXHB-24 combustible floor base is required when cer-tain units are applied downflow on combustible flooring. Failure to use the base cancause a fire resulting in property damage, personal injury or death. See clearancesfor units requiring a combustible floor base. See the accessory section in this manualfor combustible floor base RXHB-.

FIGURE 6ROTATING CIRCUIT BREAKER

12

3.4 INSTALLATION IN AN UNCONDITIONED SPACEIMPORTANT: There are two pairs of coil rails in the air handler for default and counterflow application. If the air handler is installed in an unconditioned space, the two unusedcoil rails should be removed to minimize air handler surface sweating. (See Figure 5.)The coil rails can be easily removed by taking off the 6 mounting screws from both sidesof the cabinet.

4.0 ELECTRICAL WIRINGField wiring must comply with the National Electric Code (C.E.C. in Canada) and anyapplicable local ordinance.

4.1 POWER WIRINGIt is important that proper electrical power is available for connection to the unit modelbeing installed. See the unit nameplate, wiring diagram and electrical data in the installa-tion instructions.

• If required, install a branch circuit disconnect of adequate size, located within sight of,and readily accessible to the unit.

• IMPORTANT: After the Electric Heater is installed, units may be equipped with one,two, or three 60 amp. circuit breakers. These breaker(s) protect the internal wiring inthe event of a short circuit and serve as a disconnect. Circuit breakers installed withinthe unit do not provide over-current protection of the supply wiring and therefore maybe sized larger than the branch circuit protection.

• Supply circuit power wiring must be 75°C minimum copper conductors only. SeeElectrical Data in this section for ampacity, wire size and circuit protector requirement.Supply circuit protective devices may be either fuses or “HACR” type circuit breakers.

! WARNINGDisconnect all power to unit before installing or servicing. More than one disconnectswitch may be required to de-energize the equipment. Hazardous voltage can causesevere personal injury or death.

FIGURE 7INDOOR COIL AND DRAIN PAN SET-UP

A-1037-01

HORIZONTAL ADAPTERKIT

REAR WATER CATCHER

TOP AIR STOP

STRAPS

VAPOR LINECONNECTION

FRONT WATERCATCHER

PRIMARYDRAIN

CONNECTION

LIQUID LINECONNECTION

VERTICALDRAIN PAN

AUXILIARYHORIZONTAL

DRAINCONNECTION

AUXILIARYUPFLOW/DOWNFLOWDRAIN CONNECTION

13

• Power wiring may be connected to either the right, left side or top. Three 7/8”, 13/32”,131/32” dia. concentric knockouts are provided for connection of power wiring to unit.

• Power wiring is connected to the power terminal block(s) in unit control compartment.

4.2 CONTROL WIRINGIMPORTANT: Class 2 low voltage control wire should not be run in conduit with powerwiring and must be separated from power wiring, unless Class 1 wire of proper voltagerating is used.

• Low voltage control wiring should be 18 AWG color-coded (105°C minimum). Forlengths longer than 100 ft., 16 AWG wire should be used.

• Low voltage control connections are made by extending wires from top of air handlerusing wire nuts.

• See wiring diagrams attached to indoor and outdoor sections to be connected

• Do not leave excess field control wiring inside unit, pull excess control wire to outsideof unit and provide strain relief for field control wiring on inside of cabinet at pointwiring penetrates cabinet.

• Make sure, after installation, separation of control wiring and power wiring has beenmaintained.

4.3 GROUNDING

• Grounding may be accomplished by grounding metal conduit when installed in accor-dance with electrical codes to the unit cabinet.

• Grounding may also be accomplished by attaching ground wire(s) to ground lug(s)provided in the unit wiring compartment.

• Ground lug(s) are located close to wire entrance on left side of unit (upflow). Lug(s)may be moved to marked locations near wire entrance on right side of unit (upflow), ifalternate location is more convenient.

• Use of multiple supply circuits require grounding of each circuit to lug(s) provided inunit.

! WARNINGThe unit must be permanently grounded. Failure to do so can result in electricalshock causing personal injury or death.

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITSThermostatLoad-Amps

3.02.52.0

16161850

141416100

121214150

101212200

101012250

101010300

SOLID COPPER WIRE - AWG.

Length of Run - Feet (1)(1) Wire length equals twice the run distance.

NOTE: Do not use control wiring smaller than No. 18 AWG between thermostat and outdoor unit.

14

4.4 BLOWER MOTOR ELECTRICAL DATA

MAXIMUMCIRCUIT

PROTECTOR

MINIMUMCIRCUITAMPACITY

CIRCUITAMPSSPEEDSRPMHPHERTZPHASEVOLTAGE

NOMINALCOOLINGCAPACITY(TONS)

11/2 & 2 208/240 1 60 1/3 300-1100 2 2.2 3 15

21/2 & 3 208/240 1 60 1/2 300-1100 2 3.1 4.0 15

31/2, 4 208/240 1 60 3/4 300-1100 2 4.0 5.0 15

5 208/240 1 60 3/4 300-1100 2 4.4 6 15

15

4.5 ELECTRIC HEAT ELECTRICAL DATA

HIGH KW ELECTRIC HEAT ELECTRICAL DATA: (-)HKA, (-)HKL

RXBH-17A03J 2.25/3.0 1/60 1-3.0 SINGLE 10.8/12.5 2.2 17/19 20/20RXBH-17A05J 3.6/4.8 1/60 1-4.8 SINGLE 17.3/20.0 2.2 25/28 25/30RXBH-17A07J 5.4/7.2 1/60 2-3.6 SINGLE 26.0/30.0 2.2 36/41 40/45RXBH-17A10J 7.2/9.6 1/60 2-4.8 SINGLE 34.6/40.0 2.2 46/53 50/60

(-)HKA/(-)HKL RXBH-17A13J 9.4/12.5 1/60 3-4.17 SINGLE 45.1/52.1 2.2 60/68 60/701-1/2 & 2 3.1/4.2 1/60 1-4.17 MULTIPLE CKT 1 15.0/17.4 2.2 22/25 25/25

17RXBH-17A13J

6.3/8.3 1/60 2-4.17 MULTIPLE CKT 2 30.1/34.7 0 38/44 40/45RXBH-17A07C 5.4/7.2 3/60 3-2.4 SINGLE 15.0/17.3 2.2 22/25 25/25RXBH-17A10C 7.2/9.6 3/60 3-3.2 SINGLE 20.0/23.1 2.2 28/32 30/35RXBH-17A13C 9.4/12.5 3/60 3-4.17 SINGLE 26.1/30.1 2.2 36/41 40/45RXBH-17A03J 2.25/3.0 1/60 1-3.0 SINGLE 10.8/12.5 3.1 18/20 20/20RXBH-17A05J 3.6/4.8 1/60 1-4.8 SINGLE 17.3/20.0 3.1 26/29 30/30RXBH-17A07J 5.4/7.2 1/60 2-3.6 SINGLE 26.0/30.0 3.1 37/42 40/45RXBH-17A10J 7.2/9.6 1/60 2-4.8 SINGLE 34.6/40.0 3.1 48/54 50/60RXBH-17A13J 9.4/12.5 1/60 3-4.17 SINGLE 45.1/52.1 3.1 61/69 70/70

3.1/4.2 1/60 1-4.17 MULTIPLE CKT 1 15.0/17.4 3.1 23/26 25/30(-)HKA/(-)HKL

RXBH-17A13J6.3/8.3 1/60 2-4.17 MULTIPLE CKT 2 30.1/34.7 0 38/44 40/45

2-1/2 & 3 RXBH-17A15J 10.8/14.4 1/60 3-4.8 SINGLE 51.9/60.0 3.1 69/79 70/8017 3.6/4.8 1/60 1-4.8 MULTIPLE CKT 1 17.3/20.0 3.1 26/29 30/30


RXBH-17A18J 12.8/17.0 1/60 3-5.68 SINGLE 61.6/70.8 3.1 81/93 90/1004.3/5.7 1/60 1-5.68 MULTIPLE CKT 1 20.5/23.6 3.1 30/34 30/35


RXBH-17A07C 5.4/7.2 3/60 3-2.4 SINGLE 15.0/17.3 3.1 23/26 25/30RXBH-17A10C 7.2/9.6 3/60 3-3.2 SINGLE 20.0/23.1 3.1 29/33 30/35RXBH-17A13C 9.4/12.5 3/60 3-4.17 SINGLE 26.1/30.1 3.1 37/42 40/45RXBH-17A15C 10.8/14.4 3/60 3-4.8 SINGLE 30.0/34.6 3.1 42/48 45/50RXBH-17A18C 12.8/17.0 3/60 3-5.68 SINGLE 35.5/41.0 3.1 49/56 50/60RXBH-24A05J 3.6/4.8 1/60 1-4.8 SINGLE 17.3/20.0 4.0 27/30 30/30RXBH-24A07J 5.4/7.2 1/60 2-3.6 SINGLE 26.0/30.0 4.0 38/43 40/45RXBH-24A10J 7.2/9.6 1/60 2-4.8 SINGLE 34.6/40.0 4.0 49/55 50/60RXBH-24A15J 10.8/14.4 1/60 3-4.8 SINGLE 51.9/60.0 4.0 70/80 70/80

3.6/4.8 1/60 1-4.8 MULTIPLE CKT 1 17.3/20.0 4.0 27/30 30/30RXBH-24A15J

7.2/9.6 1/60 2-4.8 MULTIPLE CKT 2 34.6/40.0 0.0 44/50 45/50RXBH-24A18J 12.8/17.0 1/60 4-4.26 SINGLE 61.6/70.8 4.0 82/94 90/100

6.4/8.5 1/60 2-4.26 MULTIPLE CKT 1 30.8/35.4 4.0 44/50 45/50RXBJ-24A18J

6.4/8.5 1/60 2-4.26 MULTIPLE CKT 2 30.8/35.4 0.0 39/45 40/45(-)HKA/(-)HKL RXBH-24A20J 14.4/19.2 1/60 4-48 SINGLE 69.2/80 4.0 92/105 100/1103-1/2 & 4 7.2/9.6 1/60 2-4.8 MULTIPLE CKT 1 34.6/40.0 4.0 49/55 50/60

21 RXBH-24A20J 7.2/9.6 1/60 2-4.8 MULTIPLE CKT 2 34.6/40.0 0.0 44/50 45/50RXBH-24A25J 18.0/24.0 1/60 6-4.0 SINGLE 86.4/99.9 4.0 113/130 125/150


6.0/8.0 1/60 2-4.0 MULTIPLE CKT 2 28.8/33.3 0.0 36/42 40/45(4-ton only)

6.0/8.0 1/60 2-4.0 MULTIPLE CKT 3 28.8/33.3 0.0 36/42 40/45RXBH-24A07C 5.4/7.2 3/60 3-2.4 SINGLE 15.0/17.3 4.0 24/27 25/30RXBH-24A10C 7.2/9.6 3/60 3-3.2 SINGLE 20.0/23.1 4.0 30/34 30/35RXBH-24A15C 10.8/14.4 3/60 3-4.8 SINGLE 30.0/34.6 4.0 43/49 45/50RXBH-24A18C 12.8/17.0 3/60 3-2.84 SINGLE 35.6/41.0 4.0 50/57 50/60RXBH-24A20C* 14.4/19.2 3/60 3-3.2 SINGLE 40.0/46.2 4.0 55/63 60/70

7.2/9.6 3/60 3-3.2 MULTIPLE CKT 1 20.0/23.1 4.0 30/34 30/35RXBH-24A20C

7.2/9.6 3/60 3-3.2 MULTIPLE CKT 2 20.0/23.1 0.0 25/29 25/30RXBH-24A25C* 18.0/24.0 3/60 6-4.0 SINGLE 50.0/57.8 4.0 68/78 70/80

RXBH-24A25C 9.0/12.0 3/60 3-4.0 MULTIPLE CKT 1 25.0/28.9 4.0 37/42 40/45(4-ton only) 9.0/12.0 3/60 3-4.0 MULTIPLE CKT 2 25.0/28.9 0.0 32/37 35/40

NORMALCOOLING

CAPACITY TONSCABINET SIZE

MODELNO.

HEATERKW

208/240VPH/HZ

NO.ELEMENTS- KW PER

TYPE SUPPLYCIRCUIT

SINGLE CIRCUITMULTIPLE CIRCUIT

CIRCUITAMPS.

MOTORAMPACITY


MAXIMUMCIRCUIT

PROTECTION

Installation of the UL Listed original equipment manufacturer provided heater kits listed in the following table is recommended for allauxiliary heating requirements.

16

4.5 Electric Heat Electrical Data: (-)HKA/(-)HKL - continued

RXBH-24A05J 3.6/4.8 1/60 1-4.8 SINGLE 17.3/20.0 4.4 30/35 28/31

RXBH-24A07J 5.4/7.2 1/60 2-3.6 SINGLE 26.0/30.0 4.4 38/43 40/45

RXBH-24A10J 7.2/9.6 1/60 2-4.8 SINGLE 34.6/40.0 4.4 49/56 50/60

RXBH-24A15J 10.8/14.4 1/60 3-4.8 SINGLE 51.9/60.0 4.4 71/81 80/90

3.6/4.8 1/60 1-4.8 MULTIPLE CKT1 17.3/20.0 4.4 28/31 30/35RXBH-24A15J

7.2/9.6 1/60 2-4.8 MULTIPLE CKT 2 34.6/40.0 0 44/50 45/50

RXBH-24A18J 12.8/17 1/60 4-4.26 SINGLE 61.6/70.8 4.4 83/94 90/100


6.4/8.5 1/60 2-4.26 MULTIPLE CKT 2 30.8/35.4 0 39/45 40/45

RXBH-24A20J 14.4/19.2 1/60 4-4.8 SINGLE 69.2/80 4.4 93/106 100/110


7.2/9.6 1/60 2-4.8 MULTIPLE CKT 2 34.6/40.0 0 44/50 45/50

RXBH-24A25J 18.0/24.0 1/60 6-4.0 SINGLE 86.4/99.9 4.4 114/131 125/150

6.0/8.0 1/60 2-4.0 MULTIPLE CKT 1 28.8/33.3 4.4 42/48 45/50

(-)HKA/(-)HKL RXBH-24A25J 6.0/8.0 1/60 2-4.0 MULTIPLE CKT 2 28.8/33.3 0 36/42 40/45

4 & 5 6.0/8.0 1/60 2-4.0 MULTIPLE CKT 3 28.8/33.3 0 36/42 40/45

24 RXBH-24A30J 21.6/28.8 1/60 6-4.8 SINGLE 103.8/120. 4.4 136/156 150/175


7.2/9.6 1/60 2-4.8 MULTIPLE CKT 2 34.6/40.0 0 44/50 45/50(5-ton only)

7.2/9.6 1/60 2-4.8 MULTIPLE CKT 3 34.6/40.0 0 44/50 45/50

RXBH-24A07C 5.4/7.2 3/60 3-2.4 SINGLE 15.0/17.3 4.4 25/28 25/30

RXBH-24A10C 7.2/9.6 3/60 3-3.2 SINGLE 20.0/23.1 4.4 31/35 35/35

RXBH-24A15C 10.8/14.4 3/60 3-4.8 SINGLE 30.0/34.6 4.4 43/49 45/50

RXBH-24A18C 12.8/17.0 3/60 3-2.84 SINGLE 35.6/41.0 4.4 50/57 50/60

RXBH-24A20C* 14.4/19.2 3/60 3-3.2 SINGLE 40.0/46.2 4.4 56/64 60/70


7.2/9.6 3/60 3-3.2 MULTIPLE CKT 2 20.0/23.1 0 25/29 25/30

RXBH-24A25C* 18.0/24.0 3/60 6-4.0 SINGLE 50.0/57.8 4.4 68/78 70/80


9.0/12.0 3/60 3-4.0 MULTIPLE CKT 2 25.0/28.9 0 32/37 35/40

RXBH-24A30C* 21.6/28.8 3/60 6-4.8 SINGLE 60.0/69.4 4.4 81/93 90/100

RXBH-24A30C 10.8/14.4 3/60 3-4.8 MULTIPLE CKT 1 30.0/34.7 4.4 43/50 45/50(5-ton only) 10.8/14.4 3/60 3-4.8 MULTIPLE CKT 2 30.0/34.7 0 38/44 40/45

NORMALCOOLING

CAPACITY TONSCABINET SIZE

MODELNO.

HEATERKW

208/240VPH/HZ

NO.ELEMENTS- KW PER

TYPE SUPPLYCIRCUIT

SINGLE CIRCUITMULTIPLE CIRCUIT

CIRCUITAMPS.

MOTORAMPACITY


MAXIMUMCIRCUIT

PROTECTION

NOTES:* Values only. No single point kit available.• Electric heater BTUH - (heater watts + motor watts) x 3.414 (see airflow table for motor watts.)• Supply circuit protective devices may be fuses or “HACR” type circuit breakers.• Largest motor load is included in single circuit and multiple circuit 1.• If non-standard fuse size is specified, use next size larger fuse size.• J Voltage (230V) signal phase air handler is designed to be used with single or three phase 230 volt electric heaters. In the caseof connecting 3-phase power to the air handler terminal block without the heater, bring only two leads to the terminal block. Cap,insulate and fully secure the third lead.

• If the kit is listed under both single and multiple circuits, the kit is shipped from factory as multiple circuits. For single phase appli-cation, Jumper bar kit RXBJ-A21 and RXBJ-A31 can be used to convert multiple circuits to a single supply circuit. Refer toAccessory Section for details.

• The airflow for continuous fan is set 50% of the cooling airflow.

17

4.5AHEATER KIT SUPPLEMENTAL INFORMATION

Heater Kit Supplemental Information: What allows the manufacturer to use standard Circuit Breakersup to 60 amps inside the air handler, when using an approved Heater Kit?

National Electric Code (Section 424-22b) and our UL requirements allow us to subdivide heating elementcircuits, of less than 48 amps, using breakers of not more than 60 amps and, additionally by, NEC 424-3b, arating not less than 125 percent of the load and NEC 424-22c, which describes the supplementary overcur-rent protection required to be factory-installed within, or on the heater. The breakers in the heater kit are not,and have never been, by NEC, intended to protect power wiring leading to the air handler unit. The breakersin the heating kit are for short circuit protection. All internal unit wiring, where the breakers apply, has beenUL approved for short circuit protection.

Ampacity, (not breaker size), determines supply circuit wire size. The ampacity listed on the unit rating plateand the Maximum and Minimum circuit breaker size (noted above) or in the units specification sheet orinstallation instructions provides the information to properly select wire and circuit breaker/protector size. TheNational Electric Code (NEC) specifies that the supply or branch circuit must be protected at the source.

These are therequired maxi-mum and mini-mum circuitbreaker sizesfor overcurrentprotection andshould not beconfused withthe size of thebreakersinstalled in theheater kit.

Contractorshould “markor check” theleft column forthe kit installedIf a heater

kit is listedbothSingleand Multi-circuit, thekit isshippedas a Multi-circuit andwillrequire asinglepoint kit

Only listed kits can be applied

MARK HEATER INSTALLED/L’APPAREIL DE CHAUFFAGE DE MARQUE A INSTALLE

(-)HLA-HM4821JA

AIR CONDITIONING DIVISION

18

5.0 ECM MOTOR INTERFACE CONTROL BOARD5.1 ECM MOTOR INTERFACE CONTROL AND SETTINGSThe (-)HKA and (-)HKL series air handlers have ECM blower motors, which deliver a constantlevel of airflow over a wide range of external static pressures (up to 1.0" W.C.). The interfaceboard provides the required communications between the thermostat and the ECM blowermotor. The (-)HKA and (-)HKL series of air handlers feature:

• An automotive-style ATC blade fuse for transformer protection (3 amp).

• An on-board LED to indicate blower CFM.

There is a bank of 10 DIP switches on the interface board that define the operation of theECM motor (see Table 1).

Refer to Figure 8 for switch identification and factory default settings.

IMPORTANT: Disconnect power to air handler when changing DIP switch positions. Even ifblower is not operating, the motor will not recognize changes in DIP switch positions until unitpower is removed and then restored.

FIGURE 8ECM MOTOR FACTORY SETTINGS

TABLE 1SWITCH FUNCTIONS

Switch Function1 & 2 Cooling Airflow Settings3 & 4 Cooling Airflow Adjustment5 & 6 Heating Airflow Settings7 & 8 Cooling Delay Profiles9 & 10 On-Demand Dehumidification

5.2 USING THE ON-BOARD LED TO DETERMINE BLOWER CFMThe (-)HKA and (-)HKL interface board LED (see Figure 9) indicates blower output by flashingone (1) second for every 100 CFM of airflow. The LED will pause 1/10 second between eachflash. After the blower CFM has been displayed, the LED will illuminate dimly for 10 secondsbefore repeating the sequence. (See Table 2.)

NOTE: If airflow is not a multiple of 100 CFM, the last LED flash is a fraction of a second of100 CFM.

5.3 COOLING AND HEAT PUMP HEATING MODE AIRFLOW SETTINGS(SEE FIGURE 10)The (-)HKA and (-)HKL-series of air handlers allow a wide range of airflow settings for coolingand heat pump operation. Each air handler is factory programmed and shipped with the opti-mum airflow for cooling and heating performance. These airflow settings are selected via DIPswitches 1 & 2 on the interface board. DIP switches 1 & 2 allow the user to tailor the airflowfor the particular installation.

19

TABLE 2LED FLASH CODES

INTERFACEBOARD

DIP SWITCHSETTINGS

1200 CFM

600 CFM

950 CFM

LED OUTPUT

• Flashes 12 times• Illuminate dimly 10 seconds, repeat sequence

• Flashes 6 times• Illuminate dimly 10 seconds, repeat sequence

• Flashes 9 times, flash once for 1/2 second• Illuminate dimly 10 seconds, repeat sequence

FIGURE 9IFC BOARD

LED

FUSE

20

5.4 COOLING/HEATING AIRFLOW ADJUSTMENTS (SEE FIGURE 10)Cooling/heating airflow may be adjusted +10% or –10% from nominal airflow using switches 3& 4.

Refer to Figure 11 for switch positions to achieve the desired adjustments in airflow.

NOTE: Continuous fan speed is NOT affected by switches 3 & 4.IMPORTANT: The use of On Demand Dehumidification overrides the cooling airflow adjust-ments when high humidity is detected by a dehumidifying thermostat or humidistat when con-nected to the ODD wire (See Figure 14). Refer to the Cooling Mode Dehumidification sectionfor more information.

FIGURE 11COOLING AIRFLOW ADJUSTMENTS

COOLINGSELECTION SWITCH 3 SWITCH 4 AIRFLOW

POSITION POSITION ADJUSTMENTA OFF OFF NONE

B ON OFF 10%

C OFF ON -10%

D ON ON NONE

ON

ON

ON

ON

A

3 4 3 4 3 4 3 4

B C D

A OFF OFF 800 800 1200 1200 1600 1600 1800 1800

B ON OFF 800 800 1200 1200 1600 1600 1800 1800

C OFF ON 600 600 1000 1000 1400 1400 1600 1600

D ON ON 600 600 1000 1000 1400 1400 1600 1600

FIGURE 10AIRFLOW SETTINGS

SELECTIONSWITCH 1AND 5

POSITION

SWITCH 2AND 6

POSITION

(-)HKA/(-)HKL 17/11/2 & 2 TON

(-)HKA/(-)HKL 17/21/2 & 3 TON

(-)HKA/(-)HKL 21/31/2 & 4 TON

Y1 Y2 Y1 Y2 Y1 Y2

(-)HKA/(-)HKL 24/4 & 5 TON

Y1 Y2

COOLING/HEATING AIRFLOWCABINET SIZE/COOLING CAPACITY

ON

ON

ON

ON

A

1 2 1 2 1 2 1 2

B C D

21

5.5 ELECTRIC HEAT AIRFLOW SETTINGS/ADJUSTMENTSDIP switches 5 & 6 control electric heat air-flow levels on (-)HKA and (-)HKL air-handlers.Electric heat air-flow must be set to match the cooling/heat pump air-flow for proper opera-tion. Therefore, settings for DIP switches 5 & 6 should match DIP switches 1 & 2 respectively.

NOTE: Cooling/heating air-flow adjustments using DIP switches 3 & 4 also affect electric heatairflow on (-)HKA and (-)HKL air-handlers.

5.6 COOLING DELAY PROFILESThe (-)HKA and (-)HKL air handlers are shipped with a default 30 second blower OFF delayprofile for maximum efficiency.

IMPORTANT: Blower ON delay profiles are not used in heating mode.

5.7 COOLING MODE DEHUMIDIFICATION“On Demand Dehumidification”, ODD, terminal input allows the user to have automatic dehu-midification in the cooling mode that is controlled by the user’s dehumidifying thermostat orhumidistat setting. When the humidity exceeds the humidistat setting, the airflow is decreasedby a preprogrammed amount. This results in higher latent capacity and increases the level ofcomfort.

Use of the On Demand Dehumidification feature is important with the (-)HKA and (-)HKL airhandlers. These systems typically have a latent capacity between 23% to 25% of total systemcapacity. On Demand Dehumidification drops cooling airflow to boost latent capacity withoutsacrificing total system capacity.

The interface board “ODD” terminal input is designed to be used with a dehumidifying thermo-stat or a traditional humidistat (see Figure 14). For proper operation, the dehumidifying ther-mostat or humidistat must conform to these conditions:

IMPORTANT: A humidistat can be used for dehumidification as long as it is the type wherethe contacts close when the humidity is low. Dehumidistat 41-25066-02 can also be usedsince its contacts close when the humidity is low. Other dehumidistats are not compatible withthe interface board. Typical dehumidistats apply a 24V signal when humidity is high and areincompatible with the interface board.

Refer to the typical thermostat wiring section (See Figures 12-17) for recommended dehumid-ifying thermostats.

TABLE 3ODD TERMINAL

INDOOR INPUT TO “ODD”AMBIENT TERMINAL

CONDITION (FROM HUMIDISTAT)HIGH HUMIDITY Ø VACLOW HUMIDITY 24 VAC

22

w

W2

G

W1

B

ODD

C

R

Air Handler

G Y C R

Single-Stage A/C Thermostat

A/C Outdoor Unit

Y

C

Y2

Y

Field Installed Line Voltage

-

WIRING INFORMATION

Factory Standard -

W/BL

G/BK

Y

W/BK

BL

G/Y

BR

R

Y/BL

FIGURE 12TYPICAL THERMOSTAT: STRAIGHT COOLING WITH ELECTRIC HEAT

FIGURE 13TYPICAL THERMOSTAT: STRAIGHT COOLING WITH ELECTRICHEAT AND USING A HUMIDISTAT FOR DEHUMIDIFICATION

W2

G

Y

W1

B

ODD

C

R

Air Handler

G Y C R

Single-Stage A/C Thermostat

A/C Outdoor Unit

Y

C

Humidistat

Y2


-

WIRING INFORMATION

Factory Standard -

W

W/BL

G/BK

Y

W/BK

BL

G/Y

BR

R

Y/BL

FIGURE 14TYPICAL THERMOSTAT: STRAIGHT COOLING WITH ELECTRIC HEATUSING ATWO-STAGE FOR DEHUMIDIFYING THERMOSTAT

W2

G

Y

W1

B

ODDC

R

Air Handler

C R

Two-Stage A/C Thermostat

A/C Outdoor Unit

Y

C

W GW2 Y

Y2

Y2 D


-

WIRING INFORMATION

Factory Standard -

W/BL

G/BK

Y

W/BK

BL

G/Y

BR

R

Y/BL

B

W2

G

Y

W1

B

ODD

C

R

Air Handler

Y G W2 E

Heat Pump Thermostat

Heat Pump Outdoor Unit

YB

C R

RD

C

Y


-

WIRING INFORMATION

Factory Standard -

W/BL

G/BK

Y

W/BK

G/Y

BR

BL

R

Y/BL

FIGURE 15TYPICAL THERMOSTAT: HEAT PUMPWITH ELECTRIC HEAT

FIGURE 16TYPICAL THERMOSTAT: HEAT PUMP WITH ELECTRIC HEAT ANDUSING A HUMIDISTAT FOR DEHUMIDIFICATION

B

W2

G

Y

W1

B

ODD

C

R

Air Handler

Y G W2 E

Heat Pump Thermostat


YB

HumidistatC R

RD

C

Y2


-

WIRING INFORMATION

Factory Standard -

W/BL

G/BK

Y

W/BK

BL

G/Y

BR

R

Y/BL

FIGURE 17TYPICAL THERMOSTAT: HEAT PUMP WITH ELECTRIC HEATUSING A TWO-STAGE THERMOSTAT FOR DEHUMIDIFICATION

B

W2

G

Y

W1

B

ODD

C

R

Air Handler

Y2 G W W2Two-Stage Heat Pump Thermostat


YB

C R

RD

C

Y1

Y2


-

WIRING INFORMATION

Factory Standard -

W/BL

G/BK

Y

W/BK

BL

G/Y

BR

R

Y/BL

5.7A Typical Thermostat Wiring Diagrams WIRE COLOR CODEBK – BLACK G – GREEN PR – PURPLE Y – YELLOWBR – BROWN GY – GRAY R – REDBL – BLUE O – ORANGE W – WHITE

23

5.8 ON DEMAND DEHUMIDIFICATION AIRFLOW ADJUSTMENTUse switches 9 & 10 to lower cooling airflow as defined in Figure 18:

IMPORTANT: Selection A turns off the input of the ODD terminal. DO NOT USE SELEC-TION A WITH A DEHUMIDIFYING THERMOSTAT OR HUMIDISTAT (refer to Figure 18).

5.8A Explanation of Selections:Selection A: Maximum Latent Removal (See Table 4)

This selection lowers cooling airflow to maximize latent removal anytime there is a call forcooling. This selection can be used in environments where there is always a high latentload as in coastal and southern regions of the USA.

NOTE: Use of selection A in excessively dry environments is not necessary and maycause unnecessary power consumption.

Selection B: Factory SettingThis is the factory setting and provides cooling airflows as defined in the COOLING AIR-FLOWS section.

Selection C: On Demand Dehumidification (See Table 5)This selection allows On Demand Dehumidification when using a dehumidifying thermo-stat or humidistat connected to the ODD wire (as shown in Figure 14). Nominal airflow isreduced by a preprogrammed amount to maximize latent removal.

IMPORTANT: A humidistat or dehumidifying thermostat MUST be connected to the ODD ter-minal when using this setting.

Selection D: No AdjustmentThis selection is the same as the factory setting and provides cooling airflows as defined inthe NOMINAL AIRFLOW ADJUSTMENT section.

FIGURE 18ON DEMAND DEHUMIDIFICATION AIRFLOW ADJUSTMENT

ON

ON

ON

ON

A

9 10 9 10 9 10 9 10

B C D

SWITCH 9 SWITCH 10SELECTION POSITION POSITION COOLING AIRFLOW ADJUSTMENT

MAXIMUM LATENT REMOVALA OFF OFF (WITHOUT ODD INPUT)NONEB ON OFF (FACTORY SETTING)

ON DEMAND DEHUMIDIFICATION1C OFF ON (WITH ODD INPUT)D ON ON NONE

SWITCH 1 SWITCH 2 SWITCH 9 SWITCH 10 17/ 17/ 21/ 24/POSITION POSITION POSITION POSITION 11/2 & 2.0 2.0 & 3.0 31/2 & 4.0 5.0

OFF OFF OFF OFF 680 1020 1360 1530

ON OFF OFF OFF 680 1020 1360 1530

OFF ON OFF OFF 510 850 1190 1360

ON ON OFF OFF 510 850 1190 1360

TABLE 4SELECTION A EXPLANATION: MAXIMUM LATENT REMOVAL

SWITCH POSITIONS CABINET SIZE/COOLING CAPACITYCFM

24

6.0 AIRFLOW PERFORMANCEAirflow performance data is based on cooling performance with a coil and no filter inplace. Select performance table for appropriate unit size, voltage and number of electricheaters to be used. Make sure external static applied to unit allows operation within theminimum and maximum limits shown in table below for both cooling and electric heatoperation. For optimum blower performance, operate the unit in the .1 [3 mm] to 1.00inches [25 mm] W.C. external static range. Units with coils should be applied with a mini-mum of .1 inch [3 mm] W.C. external static.

SWITCH 1 SWITCH 2 SWITCH 9 SWITCH 10 ODD 17 / 11/2 & 2.0 17 / 2.0 & 3.0 21 / 31/2 & 4.0 24 / 5.0POSITION POSITION POSITION POSITION INPUT Y1 Y2 Y1 Y2 Y1 Y2 Y1 Y2

NONE 680 1020 1360 1530OFF OFF OFF ON

24VAC 800 1200 1600 1800

NONE 680 1020 1360 1530ON OFF OFF ON

24VAC 800 1200 1600 1800

NONE 510 830 1190 1360OFF ON OFF ON

24VAC 600 1000 1400 1600

NONE 510 830 1190 1360ON ON OFF ON

24VAC 600 1000 1400 1600

TABLE 5SELECTION C EXPLANATION: ON DEMAND DEHUMIDIFICATION

CABINET SIZE/COOLING CAPACITYCFMSWITCH POSITIONS

25

NominalCoolingCapacityTons

ModelSize

MotorSpeedFromFactory

NominalAir-FlowCFM

BlowerSize

Motor H.P.

ECMCFM Air Delivery/RPM/Watts-230 VoltsExternal Static Pressure-InchesW.C.

0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00

613 613 656 656 658 656 656 653 651 647525 626 728 778 823 871 935 987 1025 107956 68 95 120 138 152 168 191 202 222604 603 645 644 645 642 641 637 634 629535 641 748 803 853 906 975 1032 1075 113461 75 104 131 151 167 185 210 223 245832 832 835 849 851 852 861 862 862 862649 718 775 835 886 947 999 1043 1080 1131114 132 157 183 202 232 263 290 306 339814 814 817 831 833 834 843 844 844 844666 771 828 888 939 1001 1053 1097 1134 1185131 151 177 205 226 257 290 319 336 3711001 1030 1030 1035 1035 1029 1029 1029 1029 1023652 752 812 845 923 945 1007 1065 1090 1118134 166 193 212 244 266 280 320 341 357980 1009 1009 1014 1014 1008 1008 1008 1008 1002714 814 874 907 985 1007 1069 1127 1152 1180176 208 235 254 286 308 322 362 383 3991220 1229 1229 1229 1229 1229 1238 1238 1233 1228732 831 875 930 981 1005 1077 1108 1156 1194215 253 282 314 348 362 409 426 472 4961199 1208 1208 1208 1208 1208 1217 1217 1212 1207794 893 937 992 1043 1067 1139 1170 1218 1256257 295 3245 356 390 404 451 468 514 5381395 1404 1413 1413 1411 1411 1402 1391 1380 1371731 807 859 910 968 1016 1057 1100 1128 1158240 273 308 349 383 411 436 468 496 5131379 1382 1386 1380 1373 1367 1353 1336 1320 1305765 846 902 958 1020 1073 1118 1166 1198 1233261 300 340 387 426 460 490 528 561 5841583 1583 1583 1590 1582 1566 1572 1556 1547 1539826 879 933 984 1025 1067 1119 1148 1176 1219342 375 410 454 486 523 552 585 614 6161567 1559 1551 1550 1534 1511 1509 1485 1468 1452860 919 978 1035 1082 1129 1187 1222 1255 1304363 403 444 495 534 577 613 653 688 6971607 1615 1622 1630 1637 1629 1621 1614 1606 1583612 698 747 788 835 870 914 950 981 1018225 297 334 359 410 439 469 502 532 5681587 1589 1589 1591 1591 1577 1562 1549 1534 1505658 748 802 847 899 938 987 1027 1063 1104246 325 369 401 459 495 532 572 609 6521794 1808 1808 1808 1807 1807 1807 1800 1786 1772676 739 787 840 871 923 950 994 1028 1050330 376 416 465 504 554 576 624 662 6941756 1770 1770 1769 1769 1769 1769 1762 1748 1734713 778 828 884 917 971 1000 1047 1083 1107361 410 453 505 547 600 625 676 717 752

2417No heat

2417No heat

2417with

13kw heat

2417with

13kw heat

High

High

600*

600* 10x61/3

10x61/3

High

High

800

800 10x61/3

10x61/3

3617No heat

3617with

18kw heat

3617No heat

4821No heat

4821with

20kw heat

4821No heat

4821with

25kw heat

3617with

18kw heat

High

High

1000*

1000* 10x81/2

10x81/2

1.5

1.5

2.0

2.0

2.5

2.5

High 1200 10x81/23.0

3.5

3.0

High

High

1400*

1200 10x81/2

10x103/4

4.0

3.5

High

High

1600

1400* 10x103/4

10x103/4

4.0 High 1600 10x103/4

4824No heat

4824with

25kw heat

4.0 High 1600* 11x113/4

4.0 High 1600* 11x113/4

6024No heat

6024with

30kw heat

5.0 High 1800 11x113/4

5.0 High 1800 11x113/4

6.1 AIRFLOW PERFORMANCE DATA

*To obtain the nominal airflow 600 CFM for 2417, 1000 CFM for 3617, 1400 CFM for 4821, and 1600 CFM for 4824; the DIP switches 1 and 2 mustbe set for selection C or D. See Figure 9.

26

7.0 DUCTWORKField ductwork must comply with the National Fire Protection Association NFPA 90A,NFPA 90B and any applicable local ordinance.

Sheet metal ductwork run in unconditioned spaces must be insulated and covered with avapor barrier. Fibrous ductwork may be used if constructed and installed in accordancewith SMACNA Construction Standard on Fibrous Glass Ducts. Ductwork must complywith National Fire Protection Association as tested by U/L Standard 181 for Class I AirDucts. Check local codes for requirements on ductwork and insulation.• Duct system must be designed within the range of external static pressure the unit isdesigned to operate against. It is important that the system airflow be adequate. Makesure supply and return ductwork, grills, special filters, accessories, etc. are accountedfor in total resistance. See airflow performance tables in this manual.

• Design the duct system in accordance with “ACCA” Manual “D” Design for ResidentialWinter and Summer Air Conditioning and Equipment Selection. Latest editions areavailable from: “ACCA” Air Conditioning Contractors of America, 1513 16th Street,N.W., Washington, D.C. 20036. If duct system incorporates flexible air duct, be surepressure drop information (straight length plus all turns) shown in “ACCA” Manual “D”is accounted for in system.

• Supply plenum is attached to the 3/4” duct flanges supplied on the unit around theblower outlet. Flanges are flat for shipping purposes and must be bent up along perfo-rated edge around blower opening. Be sure to bend flanges completely up so they donot interfere with air being discharged from blower.

IMPORTANT: Flanges around blower opening for attaching supply duct must be up outof blower discharge even if not used so they do not restrict airflow from blower.

IMPORTANT: If an elbow is included in the plenum close to the unit, it must not besmaller than the dimensions of the supply duct flange on the unit.

• Some units with electric heaters require 1 in. clearance to supply plenum and branchducts to combustible material for the first 3 feet from the unit. See CLEARANCES.

• A 3/4” return duct flange is supplied on all sides of the air inlet opening of the unit coilcasing. If the unit is to be installed without a coil casing (no indoor coil), a 3/4”flange issupplied on the back and sides of the air inlet opening of the blower casing. No flangeis provided on the front of the opening to the blower casing. If return duct is attachedto the inlet of the blower casing, the front flange of the duct should be run up into theopening or 90° brake made on the front flange to tape to the front of the blower cas-ing.

• IMPORTANT: The front flange on the return duct if connected to the blower casingmust not be screwed into the area where the power wiring is located. Drills or sharpscrew points can damage insulation on wires located inside unit.

• Return duct flanges on blower or coil casing are flat for shipping purposes and mustbe bent out along perforated edge around opening.

• Secure the supply and return ductwork to the unit flanges, using proper fasteners forthe type of duct used and tape the duct-to-unit joint as required to prevent air leaks.

! WARNINGDo not, under any circumstances, connect return ductwork to any other heat produc-ing device such as fireplace insert, stove, etc. Unauthorized use of such devicesmay result in fire, carbon monoxide poisoning, explosion, personal injury or propertydamage.

27

8.0 REFRIGERANT CONNECTIONSKeep the coil connections sealed until refrigerant connections are to be made. See theInstallation Instructions for the outdoor unit for details on line sizing, tubing installation,and charging information.

Coil is shipped with a low (5 - 10 PSIG) pressure charge of dry nitrogen. Evacuate thesystem before charging with refrigerant.

Install refrigerant tubing so that it does not block service access to the front of the unit.

Nitrogen should flow through the refrigerant lines while brazing.

Use a brazing shield to protect the cabinet’s paint from being damaged by torch flames.

After the refrigerant connections are made, seal the gap around the connections withpressure sensitive gasket. If necessary, cut the gasket into two pieces for a better seal.

8.1 TEV SENSING BULBIMPORTANT: DO NOT perform any soldering with the TEV bulb attached to any line.

After soldering operations have been completed, clamp the TEV bulb securely on thesuction line at the 10 to 2 o’clock position with the strap provided in the parts bag.

Insulate the TEV sensing bulb and suction line with the provided pressure sensitive insu-lation (size 4” x 7”) and secure with provided wire ties.

IMPORTANT: TEV sensing bulb should be located on a horizontal section of suctionline, just outside of coil box.

8.2 CONDENSATE DRAIN TUBINGConsult local codes or ordinances for specific requirements.

IMPORTANT:When making drain fitting connections to the drain pan, use a thin layer ofTeflon paste, silicone or Teflon tape and install hand tight.

IMPORTANT:When making drain fitting connections to drain pan, do not overtighten.Overtightening fittings can split pipe connections on the drain pan.

• Install drain lines so they do not block service access to front of the unit. Minimumclearance of 24 inches is required for filter, coil or blower removal and service access.

• Make sure unit is level or pitched slightly toward primary drain connection so thatwater will drain completely from the pan. (See Figure 18.)

• Do not reduce drain line size less than connection size provided on condensate drainpan.

• All drain lines must be pitched downward away from the unit a minimum of 1/8” perfoot of line to ensure proper drainage.

• Do not connect condensate drain line to a closed or open sewer pipe. Run conden-sate to an open drain or outdoors.

• The drain line should be insulated where necessary to prevent sweating and damagedue to condensate forming on the outside surface of the line.

28

• Make provisions for disconnecting and cleaning of the primary drain line should itbecome necessary. Install a 3 in. trap in the primary drain line as close to the unit aspossible. Make sure that the top of the trap is below connection to the drain pan toallow complete drainage of pan (See Figure 19).

• Auxiliary drain line should be run to a place where it will be noticeable if it becomesoperational. Occupant should be warned that a problem exists if water should beginrunning from the auxiliary drain line.

• Plug the unused drain connection with the plugs provided in the parts bag, using athin layer of teflon paste, silicone or teflon tape to form a water tight seal.

• Test condensate drain pan and drain line after installation is complete. Pour waterinto drain pan, enough to fill drain trap and line. Check to make sure drain pan isdraining completely, no leaks are found in drain line fittings, and water is drainingfrom the termination of the primary drain line.

8.3 DUCT FLANGESField-installed duct flanges (4 pieces) are shipped with units. Install duct flanges asneeded on top of the unit. (See Figure 3.)

9.0 AIR FILTER (Not Factory-Installed)If a remote filter is installed, it should be sized for a maximum of 300 feet/min. air veloci-ty for the CFM required.

IMPORTANT: Do not operate system without a filter. A filter is required to protect thecoil, blower and internal parts from excessive dirt and dust.

10.0 SEQUENCE OF OPERATION10.1 Cooling (cooling only or heat pump)• When the thermostat “calls for cooling,” the circuit between R, G and Y is completed,causing the blower to energize. This circuit also closes the contactor (CC) in the out-door unit starting the compressor (COMP) and outdoor fan motor (OFM).

10.2 Heating (electric heat only)• When the thermostat “calls for heat,” the circuit between R and W1 is completed, andthe heater sequencer (HR1) is energized. A time delay will follow then: The heatingelements (HE) and the indoor blower motor (IBM) will come on. Units with a secondheater sequencer (HR2) can be connected with the first sequencer (HR1) to W on thethermostat sub-base or connected to a second stage W2 on the sub-base.W1 on the furnace board MUST be connected for heating blower operation.

FIGURE 19CONDENSATE DRAIN TRAP

DO NOT OPERATE UNIT WITHOUTCONDENSATE DRAIN TRAP.

UNIT MUST BE SLIGHTLY INCLINEDTOWARD DRAIN CONNECTION.

DO NOT OVERTIGHTEN DRAIN FITTING

UNIT

3''

3''

29

10.3 Heating (heat pump)• When the thermostat “calls for heat,” the circuits between R and G are completed.Circuit R and B energizes the reversing valve (RV) switching it to the heating position(remains energized as long as system switch is in “heat” position). Circuit R and Yenergizes the contactor (CC) starting the outdoor fan motor (OFM), compressor(COMP), and the indoor blower motor (IBM).

• If the room temperature should continue to fall, circuit R and W2 is completed by thesecond-stage heat room thermostat. Circuit R-W2 energizes a heat sequencer (HR1).The completed circuit will energize supplemental electric heat. Units with a secondheater sequencer (HR2) can be connected with first sequencer (HR1) to W2 on thermo-stat or connected to a third heating stage W3 on the thermostat sub-base. A light onthe thermostat indicates when supplemental heat is being energized.

10.4 DEFROST• For sequence of operation for defrost controls, see outdoor heat pump installationinstructions.

• Supplemental heat during defrost can be provided by connecting the purple (PU) pig-tail in the outdoor unit to P on the indoor unit control board. This will complete the cir-cuit between R and W through a set of contacts in the defrost relay (DR) when theoutdoor heat pump is in defrost. This circuit, if connected, will temper air being dis-charged from the indoor unit during defrost.

• Defrost heat control (DHC) is wired in series in the circuit described above on unitswhere the supplemental heat is more than would be required to offset the defrostcooling capacity. Defrost heat control (DHC) is provided on the same modelsdescribed above having watt restrictors.

• When the outdoor unit goes into defrost, the circuit between R and W is completedthrough a set of contacts on the defrost relay (DR) in series with the contacts on thedefrost heat control (DHC). Purple (PU) pigtails on the indoor unit and outdoor unitsmust be connected to make circuit. During defrost, the defrost heat control (DHC)senses the air temperature leaving the indoor unit and cycles the supplemental elec-tric heat to maintain comfort (75° to 85°) air temperature and prevent objectable coldair during defrost. This limits the electric heat output to the minimum required, to con-serve energy and prevent the thermostat from being satisfied with electric heat andpreventing completion of the defrost cycle.

• For most economical operation, if cold air is not of concern during defrost, the purplewire can be left disconnected. Supplemental heat will only be engergized by a callfrom second stage room thermostat.

10.5 EMERGENCY HEAT (Heating of Heat Pump)• If selector switch on thermostat is set to the emergency heat position, the heat pumpwill be locked out of the heating circuit, and all heating will be electric heat. Jumpershould be placed between W2 and E on the thermostat sub-base so that the electricheat control will transfer to the first stage heat on the thermostat. This will allow theindoor blower to cycle on and off with the electric heat when the fan switch is in theauto position.

10.6 ROOM THERMOSTAT (ANTICIPATOR SETTING)See instructions with outdoor section, condensing unit or heat pump for recommendedroom thermostats.

• On units with one electric heat sequencer (HR1) (see wiring diagram on unit), heatanticipator setting should be .16.

• On units with two electric heat sequencers (HR1 & HR2) (see wiring diagram on unit),heat anticipator setting should be .32 if both are connected to same stage on thermo-stat. Setting should be .16 if (HR1 &HR2) are connected to separate stages.

NOTE: Some thermostats contain a fixed, non-adjustable heat anticipator. Adjustment isnot permitted.

• The thermostat should be mounted 4 to 5 feet above the floor on an inside wall of theliving room or a hallway that has good air circulation from the other rooms being con-trolled by the thermostat. It is essential that there be free air circulation at the locationof the same average temperature as other rooms being controlled. Movement of airshould not be obstructed by furniture, doors, draperies, etc. The thermostat shouldnot be mounted where it will be affected by drafts, hot or cold water pipes or air ductsin walls, radiant heat from fireplace, lamps, the sun, T.V. or an outside wall. Seeinstruction sheet packaged with thermostat for mounting and installation instructions.

NOTE: Some thermostats, particularly solid-state digital types, contain fixed, non-adjustable heat anticipators and adjustment is not permitted.

30

11.0 CALCULATIONS11.1 CALCULATING TEMPERATURE RISE• The formula for calculating air temperature rise for electric resistance heat is:

3.16 x WattsTemperature Rise °F =

CFMWhere: 3.16 = Constant, CFM = Airflow

11.2 CALCULATING BTUH HEATING CAPACITY• The formula for calculating BTUH heating capacity for electric resistance heat is:

BTUH Heating = Watts x 3.412

Where: 1 kW = 1000 Watts, 3.412 = Btuh/Watt

11.3 CALCULATING AIRFLOW CFM• The formula for calculating airflow using temperature rise and heating BTUH for unitswith electric resistance heat is:

Heating BTUHCFM =

1.08 x Temp. Rise

11.4 CALCULATING CORRECTION FACTOR• For correction of electric heat output (kW or BTUH) or temperature rise at voltagesother than rated voltage multiply by the following correction factor:

Applied Voltage2

Correction Factor =Rated Voltage2

31

! WARNINGUnits with circuit breaker(s) meet requirements as a service disconnect switch, how-ever, if access is required to the line side (covered) of the circuit breaker, this side ofthe breaker(s) will be energized with the breaker(s) de-energized. Contact with theline side can cause electrical shock resulting in personal injury or death.

13.0 MAINTENANCEFor continuing high performance, and to minimize possible equipment failure, it isessential that periodic maintenance be performed on this equipment. Consult your localdealer as to the proper frequency of maintenance and the availability of a maintenancecontract.

IMPORTANT: Before performing any service or maintenance procedures, read all“WARNINGS” listed in these installation instructions.

12.0 PRE-START CHECKLIST

PRE-START CHECKLISTIs unit properly located, level, secure and service-able?

Has auxiliary pan been provided under the unit withseparate drain? (Units installed above a finishedceiling).

Is condensate line properly sized, run, trapped,pitched and tested?

Is ductwork correctly sized, run, taped and insulat-ed?

Have all cabinet openings and wiring been sealedwith caulking?

Is the filter clean, in place and of adequate size?

Is the wiring tight, correct and to the wiring diagram?

Is the unit properly grounded and protected (fused)?

Is the thermostat heat anticipator been set properly?

Is the unit circuit breaker(s) rotated properly “on” up- “off” down?

Are the unit circuit breaker(s) line lug cover(s) inplace?

Are all access panels in place and secure?

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

� YES� NO

Refer to outdoor unit installation instructions for systemstart-up instructions and refrigerant charging instructions.

32

13.1 AIR FILTER (Not Factory Installed)Check the system filter every ninety days or as often as found to be necessary and ifobstructed, clean or replace at once.

IMPORTANT: Do not operate the system without a filter in place.

13.2 INDOOR COIL - DRAIN PAN - DRAIN LINEInspect the indoor coil once each year for cleanliness and clean as necessary. It is nec-essary to remove the filter and check the return air side of the coil for debris.

IMPORTANT: Do not use caustic household drain cleaners, such as bleach, in the con-densate pan or near the indoor coil. Drain cleaners will quickly damage the indoor coil.

13.3 BLOWER MOTOR AND WHEELInspect the blower motor and wheel for cleanliness. With the system air filter in place, itshould be several years before it would become necessary to clean the blower motorand wheel.

• If it becomes necessary to remove the blower assembly from the unit, see instruc-tions on removal and disassembly of motor, blower and heater parts.

• The blower motor and wheel may be cleaned by using a vacuum with a soft brushattachment. Remove grease with a mild solvent such as hot water and detergent. Becareful not to disturb the balance weights (clips) on the blower wheel blades. Do notdrop or bend wheel as balance will be affected.

13.4 LUBRICATIONThe blower motor sleeve bearings are pre-lubricated by the motor manufacturer and donot have oiling ports. Motor should be run for an indefinite period of time without addi-tional lubrication.

13.5 BLOWER ASSEMBLY REMOVAL AND REPLACEMENTRemoving the blower assembly is not required for normal service and maintenance.Removal is necessary for replacement of components such as motor, blower wheel.After extended use, removal of the blower assembly may become necessary for a thor-ough cleaning of the blower motor and wheel.

! WARNINGIf removal of the blower assembly is required, all disconnect switches supplyingpower to the airhandler must be de-energized and locked (if not in sight of unit) sothe field power wires can be safely removed from the blower assembly. Failure to doso can cause electrical shock resulting in personal injury or death.

CAUTIONIn compliance with recognized codes, it is recommended that an auxiliary drain panbe installed under all evaporator coils or units containing evaporator coils that arelocated in any area of a structure where damage to the building or building contentsmay occur as a result of an overflow of the coil drain pan or a stoppage in the prima-ry condensate drain piping. See accessory section in this manual for secondary hori-zontal drain pan RXBM-ABXX.

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• Mark field power supply wiring (for replacement) attached to terminal block or circuitbreaker(s) on blower assembly. Remove wiring from terminal block or circuit break-er(s).

• Mark low voltage control wiring (for replacement) where attached to unit control termi-nals on left side of blower housing.

• Remove a screw holding blower assembly to front channel of cabinet and pull blowerassembly from cabinet.

• To replace blower assembly, slide blower assembly into blower deck. Make sureblower assembly engages lances in deck properly. If assembly hangs up, check tomake sure top and bottom are lined up in proper locations.

• Slide blower assembly to back of cabinet and make sure it is completely engaged.

• Replace two screws holding blower assembly to front channel of cabinet. Take carenot to strip screws, just snug into place.

• Replace low voltage control wiring with wire nuts and make sure wiring is to wiringdiagram and a good connection has been made.

• Replace field power wiring to terminal block or circuit breaker(s) on control area ofblower assembly. Make sure wires are replaced as they were, check wiring diagram ifnecessary. Tighten supply power wiring securely to terminals lugs.

• Make sure wiring is within cabinet and will not interfere with access door. Make sureproper separation between low voltage control wiring and field power wiring has beenmaintained.

• Replace blower assembly control access panel before energizing equipment.

13.6 MOTOR REPLACEMENTWith the blower assembly removed, the indoor blower motor can be removed andreplaced using the following procedure:

• Remove motor leads from the motor high and low voltage plugs. Note the lead loca-tions for ease of re-assembly.

• Loosen the set screw holding the blower wheel onto the motor shaft. The shaftextends through the blower hub so that a wrench can be used on the extended shaftto break the shaft loose if necessary. Be careful not to damage the shaft. Use awheel puller on the groove in the hub if necessary.

• Loosen the bolt holding the wire motor band around the motor shell and pull themotor from the motor mount. Note the motor position in the mount for re-assembly.

• To re-assemble, insert the motor shaft through the hub in the blower wheel and orientthe motor to original position.

• For proper motor cooling, it is important that the motor be mounted the same as theoriginal, as far into the blower as practical.

• The dimension from the face of the motor end plate (shaft end) to the first wire on themotor mount band around the shell should be:

DIMENSION TONNAGE CABINET SIZE13/32" 11/2 & 2 1711/2" 21/2 & 3 1721/2" 31/2 & 4 2127/8" 5 24

• With motor held to above position and motor lead plugs oriented to the original posi-tion (the wire connectors on the motor must point straight to the supply air end of theunit and away from the return air [filter] end of the unit). Securely tighten the bolt onthe mount band to the motor shell.

• Turn the motor shaft so that the flat on the shaft is located under blower wheelsetscrew, and the blower wheel is centered in the blower housing with the same dis-tance on each side between the inlet venturi and the outside of the blower wheel.

• Re-assemble the motor wiring (high and low voltage plugs) into the motor.

IMPORTANT: DO NOT FORCE POWER PLUG INTO THE MOTOR CONNECTORBACKWARDS. The A.C. power plug to the motor has locking tabs. It has beenproven that by applying excessive force to the A.C. cable half of the connector it ispossible to force the connector in backwards. It will not seat and “click” properly butwill make connection. If A.C. power is applied with the connector reversed the motorwill be immediately destroyed.

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13.7 ECM CONTROL MODULE REPLACEMENTAlways take the following steps before replacing the control module on the end of theECM indoor blower motor.

1. HAVE THE CORRECT REPLACEMENT MODULE. These controls are factory pro-grammed for specific operating modes. Even though they look alike, different mod-ules may have different CFM characteristics.

IMPORTANT: Using the wrong control module voids all product warranties and may pro-duce unexpected results.

2. Turn off power to the equipment. Wait at least 5 minutes after disconnecting ACpower before opening the motor.

3. While not necessary, it may prove easier to remove the complete blower assemblyfrom the furnace. Unplug the two cable connectors to the motor. There are latcheson each connector. DO NOT PULL ON THE WIRES. TO REMOVE THE 16 PINPLUG, SQUEEZE THE PIN LATCH. The plugs remove easily when properlyreleased.

FIGURE 20INTERNALMOTOR PLUG AND SOCKET

FIGURE 21ECM MOTOR COMPONENTS

FIGURE 22MOTOR ALIGNMENT PIN

! WARNINGAlways have 240 volt power turned off to the furnace before attempting any replace-ment of the motor or control module. Failure to do so may result in serious equipmentdamage, personal injury or death.

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4. Locate the two standard 1/4" hex head bolts on the flat end of the motor controlmodule casting. Remove these bolts from the motor while holding the control mod-ule. DO NOT REMOVE TWO SCREWS WITH TORX HEADS.

5. The control module is still connected to the motor by a plug and cable. Carefullyrotate the control so as to gain access to the plug on the cable end. Squeeze therelease latch and gently pull the plug out of the control module. DO NOT PULL ONTHE WIRES. GRIP THE PLUG ONLY.

6. The control module is now completely detached from the motor. Use an ohmmeterto measure the resistance from each motor lead (in the motor plug just removed) tothe motor shell. This resistance must be greater than 100K ohms. Always measureto the unpainted motor end plate. If any motor lead fails this test DO NOT INSTALLTHE NEW CONTROL MODULE.

7. Verify that the replacement control module is correct. Place the new module next tothe motor and carefully insert the plug that was removed in step 5. BE SURE THEPLUG LATCHES. IT SHOULD CLICK INTO PLACE.

8. Install the new control module back on the motor. Carefully engage the alignmentpin into the appropriate mating motor hole.

9. Replace the two 1/4" hex head bolts. Tighten the bolts snugly. DO NOT OVERTIGHTEN.

IMPORTANT: Before replacing the blower motor assembly, check the installation for anyapplication fault that might have caused the motor or control module to fail. Water dam-age could show as corrosion on the inside or outside of the casting. If so, run a MoistureCheck.

10. Install the blower motor assembly back into the furnace. Follow the manufacturer’ssuggested procedures.

11. Plug the 16 pin connector into the motor. The connector is keyed. Be sure the con-nector is properly seated and latched.

12. Plug the 5 pin connector into the motor. The connector is keyed. Be sure the con-nector is properly seated and latched. OBSERVE THE PROPER ORIENTATION.DO NOT FORCE THE CONNECTOR. It plugs in very easily when properly oriented.

13. Final installation check. Be sure the motor is installed as follows.

a. Set the motor into the blower housing as originally provided from the manufactur-er.

b. Do not allow the motor mount to cover the motor vent openings.

c. Do not attach the motor mount to the motor electronics compartment.

d. The motor connectors should be straight down.

e. Have appropriate drip loops formed in the harnesses.

14. Restore 230 volt power to the system. Verify that the new motor control moduleworks properly.

13.8 BLOWER WHEEL REPLACEMENTWith the blower assembly removed and the motor assembly removed (see aboveinstructions), remove the two screws holding the blower wrap (cutoff) to the blowersides.

IMPORTANT: It is not necessary to remove heating element(s), if provided, to removethe blower wheel.

! CAUTIONReversing the 5-pin connector on the ECM motor causes immediate failure of thecontrol module.

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• With wrap (cutoff) screws removed, cut off end of blower wrap will spring up. Liftingwrap blower wheel is removed through the discharge opening in the blower housing.

• To replace, make sure wheel is oriented properly with hub to the opposite side fromthe motor. Lift blower wrap and insert blower wheel through discharge opening in theblower housing.

• Hold blower wrap down into position and replace two screws holding blower wrap toblower sides.

• See motor replacement and blower assembly instructions for remaining assemblyprocedure.

14.0 REPLACEMENT PARTSAny replacement part used to replace parts originally supplied on equipment must bethe same as or an approved alternate to the original part supplied. The manufacturer willnot be responsible for replacement parts not designed to physically fit or operate withinthe design parameters the original parts were selected for.

These parts include but are not limited to: Circuit breakers, heater controls, heater limitcontrols, heater elements, motor, motor capacitor, blower relay, control transformer,blower wheel, filter, indoor coil and sheet metal parts.

When ordering replacement parts, it is necessary to order by part number and includewith the order the complete model number and serial number from the unit data plate.(See parts list for unit component part numbers).

15.0 ACCESSORIES - KITS - PARTS• Combustible Floor Base RXHB-17, RXHB-21, RXHB-24 (for standard units) for down-flow applications, see section of this manual covering combustible floor base.

Combustible FloorModel Cabinet Size Base Model Number

17 RXHB-1721 RXHB-2124 RXHB-24

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• External Filter Base RXHF- (See Figure 23)

Model Cabinet Size Filter Size Part Number A B

17 16 x 20 [406 x 508] RXHF-17 15.70 17.5021 20 x 20 [508 x 508] RXHF-21 19.20 21.0024 25 x 20 [635 x 508] RXHF-24 22.70 25.50

Accommodate1” or 2”filter

FIGURE 23EXTERNAL FILTER BASE: RXHF-

Nominal Auxiliary Horizontal OverflowCooling Pan Accessory

Capacity Ton Model Number

11/2 - 3 RXBM-AC4831/2 - 5 RXBM-AC61

• Horizontal Adapter Kit RXHH-This horizontal adapter kit is used to convert Upflow/Downflow only models to hori-zontal flow. See the following table to order proper horizontal adapter kit.

• Auxiliary Horizontal Unit Overflow Pan Accessory RXBM-

Coil Model Horizontal Adapter Kit Horizontal Adapter KitModel Number (Single Qty.) Model Number (10-pak Qty.)

2414 RXHH-A01 RXHH-A01x102417 RXHH-A02 RXHH-A02x10

3617/3621 RXHH-A03 RXHH-A03x104821/4824 RXHH-A04 RXHH-A04x10

6024 RXHH-A05 RXHH-A05x10

• External Filter Rack: RXHF-B (See Figure 23)

Model Cabinet Size Filter Size Part Number A B17 16 x 20 RXHF-B17 16.90 20.7721 20 x 20 RXHF-B21 20.40 20.7724 25 x 20 RXHF-B24 25.00 21.04

Accommodate1” filter

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FIGURE 24EXTERNAL FILTER RACK: RXHF- B17, B21, B24

B

1.50

A

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40 CM 0108

92-20521-31 rev. 04 hka ans hkl series premium effieiciency...

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